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US2708702A - Lamp base welding - Google Patents

Lamp base welding Download PDF

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Publication number
US2708702A
US2708702A US306828A US30682852A US2708702A US 2708702 A US2708702 A US 2708702A US 306828 A US306828 A US 306828A US 30682852 A US30682852 A US 30682852A US 2708702 A US2708702 A US 2708702A
Authority
US
United States
Prior art keywords
stub
base
electrode
welding
shell
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US306828A
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English (en)
Inventor
Warren F Albrecht
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
General Electric Co
Original Assignee
General Electric Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to NL94452D priority Critical patent/NL94452C/xx
Priority to BE522412D priority patent/BE522412A/xx
Application filed by General Electric Co filed Critical General Electric Co
Priority to US306828A priority patent/US2708702A/en
Priority to DEG12523A priority patent/DE936464C/de
Priority to GB23838/53A priority patent/GB718690A/en
Application granted granted Critical
Publication of US2708702A publication Critical patent/US2708702A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J9/00—Apparatus or processes specially adapted for the manufacture, installation, removal, maintenance of electric discharge tubes, discharge lamps, or parts thereof; Recovery of material from discharge tubes or lamps
    • H01J9/24—Manufacture or joining of vessels, leading-in conductors or bases
    • H01J9/30—Manufacture of bases

Definitions

  • This invention relates to the basing operation in the manufacture of electric lamps wherein a base is fastened to the constricted neck portion of the glass bulb and permanent electrical connections are made between the lead wires and the metal parts of the base.
  • the object of the present invention is to provide a new and improved method for welding the lead-in wires of electric lamps to the metal parts of their bases.
  • Another object of the invention is to provide apparatus adapted to operate in conjunction with prior lamp finishing machines for welding the side lead-in wire to the shell of the base in the commercial production of electric lamps.
  • a weld may be effected between a lead wire and a metal part of a lamp base such as its shell through the following procedure. For instance, starting with a sealed bulb having a base seated on its neck and with the side lead-in wire drawn out between the edge of the shell and the seal shoulder, the lead-in wire is cut off to a short stub of substantial stiffness projecting a fraction of an inch from the edge of the base shell.
  • the criteria to be observed in choosing the length of stub left protruding are the following. Firstly, the stub must be short enough to have the necessary stiffness for making a good contact with an electrode pressed against it.
  • the stub should be short in order not to require a high wattage to fuse it.
  • the length of the stub must be such that when fused back into an approximately spherical 'globule' welded to the edge of the base shell, the globule should not stick out excessively nor be so large as to be unsightly.
  • a relatively low resistance atent O "ice connection must exist between the projecting stub and the metal part of the base to which it is to be welded: in the present instance of the side lead wire, this may be done by bending the stub up slightly so as to achieve a good contact connection at the root of the stub, that is, between the wire and the rim of the base at the point of emergence of the wire.
  • a relatively massive electrode is pressed against the end of the stub and a welding current having a drooping characteristic such as results from the discharge of a capacitor, is passed through the stub, the circuit being completed through the shell of the base and a suitable electrode contacting it.
  • the massive electrode which contacts the lead wire is made negative so that it operates as a cathode at the instant when, the wire having fused, a spark is produced in the gap occurring between the electrode and the end of the wire.
  • Fig. 1 is a plan view showing a fragment of a prior art lamp finishing machine and various mechanisms operating in conjunction therewith for welding electric lamps in accordance with the invention.
  • Fig. 2 is a side view of a mechanism which cuts off the side lead wire and simultaneously bends it up against the edge of the shell.
  • Fig. 3 is a side elevation view of a welding mechanism with the electrical components of the welding circuit diagrammatically illustrated.
  • Figs. 4a, 1), and 0 illustrate the sequence of events in the formation of the weld.
  • the invention may be carried out through the use of the mechanisms located at stations A and B of a prior art lamp finishing machine whereof a fragment is illustrated in plan view.
  • a prior art lamp finishing machine whereof a fragment is illustrated in plan view.
  • Such a machine is disclosed for instance in U. S. Patent 1,708,756, Fagan, and comprises a turret or turntable seen in part at 1, and suitable driving means (not shown in the drawing) for intermittently rotating the turret in a counter-clockwise direction as indicated by the curved arrows 2.
  • the glass bulbs 3 are held meet; up in holders or heads which are fastened to the turret around its periphery, and the intermittent rotation of the turret advances the bulbs to successive work stations at each index.
  • each lamp holder or head 4 comprises a bracket 5 bolted at 6 to the periphery of the turret l.
  • the bracket has a dependent portion supporting a vertical spindle 7 which carries at its upper end crow-foot shaped bulb cup 3. The spindle is urged upwards by the spring 9 causing the bulb cup to press up resiliently against the end of the bulb 3.
  • a plate 1b which receives the end button or web 11 of the base 12, and a pair of pivotable holding jaws l3, 14 which are biased together by a tension spring 15. The lamp is held firmly in the holder and the base is pressed against the bulb neck by reason of the upward pressure exerted on the bulb by the bulb cup.
  • T e jaws l4 may be pivoted open to release the base by locating a cam to engage the roller 16 affixed to the rearwardly projecting portion or" jaw 13 at the stations of the machine where opening is desired.
  • the lamp itself is released from the head 4 by a cam which engages roller 17 on spindle 7 and forces it down to relieve the pr ssure of the bulb cup on the lower end of the bulb.
  • the first step in making a welded connection of the side lead-in wire to the edge of the base shell is to cut off the side lead-in wire 19 to a short length or stub, which, in the case of a 25 Watt bulb for instance, may project approximately /s inch beyond the side of the shell.
  • the projecb ing stub is preferably bent up slightly above the horizontal while pointing radially outward so as to achieve a low resistance contact connection with the rim of the shell 29 of the base at the point where it emerges from between the shell and the neck of the bulb. All these preliminary operations y be performed simultaneously by the cutting and p tioning mechanism located at station A of the machine.
  • the mechanism comprises a pair of scissor type cutters 2i and 22 of which the upper cutter 23 is fixed in place on a bracket 23 fastenr to a standard which is bolted to a stationary frame member of the machine.
  • the lower cutter 22 is fastened on the projecting arm of a lever 2i: which is hinged on the pedestal 24.
  • the pivoting of lever 26 is achieved through a connecting rod 23 which is reciprocated vertically, in synchronism with the indexing movement of tne machine. This may be done through a rocker arm and cam system such as is illustrated in Pig. 3.
  • rod 23 is in a raised position so that the lower cutter Z2 is pivoted down, thereby allowing the projecting lead wire 19 to enter between the upper and lower cutter
  • rod 28 is reciprocated down and the projecting lip portion 22' of the lower cutter slides up past the projecting lip portion 21' of the upper cutter and the lead wire is sheared oi.
  • the continued upward movement or overtravel of lip 22' of the lower cutter bends the short remaining stub or" lead wire up slightly above the horizontal so as to achieve a good mechanical contact to the shell of the base at the point of emergence of the stub.
  • the end result of the operation is to cut off and position the projecting stub 19a of the lead wire substantially as shown in Fig. 4a.
  • the shearing operation also leaves the end or" the lead wire in the condition of a fresh cut showing clean metal without any oxide thereon; this facilitates making a good contact. to the welding electrode 31 when it is pressed against the stub.
  • the actual welding operation is performed by the mechanism located at station B and illustrated in Fig. 3.
  • the qualification of electrode 31 as massive is made with relation to the size of the lead wire 19, as will be apparent upon inspection of Figs. 3 and 4.
  • the composition of the electrode 31 is not critical and for example, electrodes of carbon, silver, copper and copper alloys, and also of tungsten have been used successfully. it has been observed however that the least pitting of the end of the electrode is achieved with an electrode composed of copper.
  • the plate 33 is supported at its forward end on a crank 3 which is hinged at 35 to the plate, and at 36 to a bracket 37 secured to the stationary frame member of the machine. At its rear end, the plate is supported by a bell crank 38 which is hinged to it at 39, and hinged at 4%) to bracket 37a secured to the member 25.
  • the offset portion of the bell crank has fastened to it at ii a connecting rod 42 which is reciprocated vertically through the usual rocker arm and cam arrangement 43, :4, the cam being driven in synchronism with the driving means of the turret so as to advance the plate radially inwards toward the bulb to enable the electrode 31 to contact the lead wire during the dwell interval of a bulb at the station.
  • the connecting rod 42 is in two parts which are linked together through a sleeve and a pair of tension springs do connected between transverse pins 47 and id in the upper and lower sections of rod respectively.
  • the upper pin 47" is free to ride in a slot 49 in the sleeve 45. This arrangement allows a lost motion through limits determined by pin 47 and its cooperating slot 49 and per mits overtravel of the lower section of the pull rod after the electrode has contacted the lead wire.
  • An adjustable stop bolt 55? limits the movement of plate 33 towards the bulb
  • the base shell is contacted at station E by a roller 51 which is rotatably fastened at the lower end of an inclined rod 52.
  • Rod 52 is hinged at 53 on a bracket 54 fixed to a stationary frame member 55 of the machine.
  • the roller Si is pressed resiliently against the edge of the base shell by the inward pivoting of the arm $2 by means or" pull rod 56 whereof the shank passes through an over-size hole at 57 in a dependent portion of the bracket 54.
  • the portion of the pull rod projecting to the rear of the bracket is provided with a spring 58 which is compressed betwecn the bracket and an end nut and washer 59.
  • a stop ring 61 on the opposite side of the bracket from the spring limits the movement or the pull rod to prevent the roller 51 from swinging too far forward into the path of travel of the bulb holders.
  • the weld is made by passing through the stub of lead wire a relatively small wattage in the form of a current starting oil at a relatively high value and dropping off very quickly to a low value.
  • the welding current has a drooping characteristic such as results from the exponential discharge of a condenser through a resistance.
  • a condenser 63 is arranged to be discharged through the lead wire, the connection being made directly from the positive side of the condenser to roller 51 which contacts the base shell, and from the negative side of the condenser, in series with an adjustable rheostat 64, to the electrode 31 which contacts the lead wire.
  • the condenser 63 may have a value of approximately 2500 microfarads and the rheostat 64 may be adjustable between 0 and 10 ohms.
  • the rheostat 64 may be set at approximately 8 ohms when the condenser 63 is charged to 200 volts at the beginning of the welding cycle.
  • the condenser 63 may be recharged in between the welding operations through any conventional system.
  • the recharging means may comprise a full-wave bridge type rectifier 65 whereof one pair of conjugate points 66 is connected in series with a control rheostat 67 across capacitor 63, and whereof the other pair of conjugate points 68 is connected across the secondary winding of a step-up transformer 69.
  • the primary winding of the transformer is energized from the usual volts 60 cycle commercial supply at terminals 71 through a switch '72.
  • Fig. 4a At the instant when the electrode 31 contacts the projecting length 19a of the lead wire, conditions are as illustrated in Fig. 4a.
  • the condenser 63 begins to discharge immediately with a heavy current, for instance 20 amperes, through the lead wire.
  • the maximum resistance in the circuit, exclusive of the control rhcostat 64, occurs in the stub 19a of the lead wire.
  • the molten sphere on the end of the wire thereupon melts the adjacent metal of the shell of the base and becomes intermingled with it as shown at 19c, thereby achievinga low resistance weld of the lead wire to the base shell and without any addition of welding metal from an neous source.
  • a shield may be positioned against the side of the bulb to protect it from the vapor and heat of the weld, or, as illustrated, a nozzle 73 supplied with air through tubing 74 may be positioned to direct an air jet upwards along the side of the bulb to blow the vapor away.
  • the method of welding a lead-in wire to a metal part of the base of an electric lamp which comprises the steps of cutting off the lead wire to a short stub of predetermined length having substantial stiffness and projecting laterally away from said metal part, making a preliminary low resistance contact connection between the root of the stub and said metal part, contacting the end of said stub with an electrode which is massive relative to said lead wire, and passing momentarily a current having a drooping characteristic through said metal part and said stub with said electrode negative in polarity and maintaining said electrode for the duration of the welding operation substantially in the position to which it was brought at the time of contacting the end of said stub so as to first form a molten bead on the end of the stub and simultaneously form an are which continues to fuse the stub and cause it to draw back until it fuses to the said metal part of the base.
  • the method of welding a lead-in wire to a metalpart of the base of an electric lamp which comprises the steps of cutting off the lead wire to a short stub of predetermined length having substantial stiffness and projecting laterally away from said metal part, making a preliminary low resistance contact connection between the root of the stub and said metal part, contacting the end of said stub with an electrode which is massive relative to said lead wire, and discharging a charged capacitor through said metal part and said stub with said electrode negative in polarity and maintaining said electrode for the duration of the welding operation substantially in the position to which it was brought at the time of contacting the end of said stub so as to first form a molten bead on the end of the stub and simultaneously form an are which continues to fuse the stub and cause it to draw back until it fuses to the said metal part of the base.
  • the method of welding a lead-in wire to a metal part of the base of an electric lamp which comprises the steps of cutting off the lead wire to a stub of predetermined length short enough to have substantial stillness and projccting laterally awayfrom said metal part, bending said stub so as to press the root thereof against the edge of the metal part to achieve a preliminary low resistance contact connection therewith while leaving the stub to extend laterally from said metal part, contacting the end of said stub with an electrode which is massive relative to said lead wire, and discharging a charged capacitor through said metal part and said stub with said electrode negative in polarity and maintaining said electrode for the duration of the welding operation substantially in the position to which it was brought at the time of contacting the end of said stub so as to first form a molten bead on the end of the stub and simultaneously form an are which continues to fuse the stub and cause it to draw back until it fuses to the said metal part of the base.
  • Lamp manufacturing apparatus comprising means for presenting a lamp bulb with a base thereon at successive work stations, means located at a station for cutting off at a predetermined point a lead wire projecting laterally from the side of the bulb at the rim of the base shell and leaving a stub of predetermined length and short enough to have substantial stiffness and means bending said stub in a direction to bring its root into firm contact with the rim of the base shell to achieve a low resistance contact connection therewith while leaving the stub to extend laterally away from said shell, an electrode which is massive relative to said lead wire, means at a successive station for bringing said electrode into contact with the end of said stub, another electrode at said successive station positioned to contact the base shell, a charged capacitor, means connecting said capacitor across said electrodes and with the negative side thereof connected to said massive electrode and means for restraining said massive electrode for the duration of the welding operation substantially at the position to which it was brought into contact with the end of said stub to permit formation of an arc which melts the said stub
  • Lamp manufacturing apparatus comprising means for presenting a lamp bulb with a base thereon at successive work stations, means located at a station for cutting 01f at a predetermined point a lead Wire projecting laterally from the side of the bulb at the rim of the base shell and leaving a stub of predetermined length and short enough to have substantial stifiness and means bending said stub in a direction to bring its root into firm contact with the rim of the base shell to achieve a low resistance contact connection therewith while leaving the stub to extend laterally away from said shell, a first electrode which is massive relative to said lead wire, a radially movable support at a successive station for pressing said electrode against the end of said stub, a second electrode at said successive station disposed to contact the base shell, a capacitor connected across said electrodes, means for charging said capacitor with the side thereof connected to said massive electrode being negative in polarity and means for restraining said massive electrode for the duration of the welding operation substantially at the position to which it was brought into contact with the end of
  • Lamp manufacturing apparatus comprising means for presenting at successive work stations a lamp bulb with a base thereon and a lead wire projecting laterally ill) ', capacitor aeross said electrodes and with the negative side thereof connected to said massive electrode, and means for restraining said massive electrode for the duration of the welding operation substantially at the position to which it was brought into contact with the end of the stub, the welding means and the severing means being so correlated that an are formed between said massive cathode and said stub is extinguished by discharging of the condenser when the predetermined length of stub has melted back and united with the base shell.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacture Of Electron Tubes, Discharge Lamp Vessels, Lead-In Wires, And The Like (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
US306828A 1952-08-28 1952-08-28 Lamp base welding Expired - Lifetime US2708702A (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
NL94452D NL94452C (pt) 1952-08-28
BE522412D BE522412A (pt) 1952-08-28
US306828A US2708702A (en) 1952-08-28 1952-08-28 Lamp base welding
DEG12523A DE936464C (de) 1952-08-28 1953-08-27 Verfahren zur Verschweissung eines Zuleitungsdrahts mit dem Sockel einer elektrischen Lampe
GB23838/53A GB718690A (en) 1952-08-28 1953-08-28 Improvements in and relating to electric lamp basing

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US306828A US2708702A (en) 1952-08-28 1952-08-28 Lamp base welding

Publications (1)

Publication Number Publication Date
US2708702A true US2708702A (en) 1955-05-17

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US306828A Expired - Lifetime US2708702A (en) 1952-08-28 1952-08-28 Lamp base welding

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US (1) US2708702A (pt)
BE (1) BE522412A (pt)
DE (1) DE936464C (pt)
GB (1) GB718690A (pt)
NL (1) NL94452C (pt)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2809279A (en) * 1954-11-24 1957-10-08 Gen Electric Lamp basing apparatus
US2832883A (en) * 1951-12-26 1958-04-29 Gen Electric Electric lamp manufacture
US3361893A (en) * 1964-08-18 1968-01-02 Sylvania Electric Prod Lamp basing method
US4091259A (en) * 1976-06-08 1978-05-23 Matsushita Electric Industrial Co., Ltd. Method for welding lead wires together
US4166943A (en) * 1976-06-08 1979-09-04 Matsushita Electric Industrial Co., Ltd. Apparatus for welding lead wires together
US5039905A (en) * 1989-07-04 1991-08-13 U.S. Philips Corporation Welding connection for an electric lamp
CN117943652A (zh) * 2024-03-26 2024-04-30 山西星心半导体科技有限公司 一种led灯泡针脚焊接机

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105127543B (zh) * 2015-09-28 2017-10-31 宁波捷胜海洋光电有限公司 一种灯泡自动银焊台

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1299150A (en) * 1918-08-16 1919-04-01 Frank L Dyer Method of manufacturing spark-plugs.
US1489093A (en) * 1919-12-08 1924-04-01 Said Mershon Welding aluminum
US1613957A (en) * 1923-01-19 1927-01-11 Westinghouse Lamp Co Method and machine for electric welding
US1706880A (en) * 1926-12-21 1929-03-26 Westinghouse Lamp Co Method of basing and soldering
US2159916A (en) * 1937-12-01 1939-05-23 Vanco Products Process for electric flash percussive welding
GB558472A (en) * 1942-07-03 1944-01-06 Standard Telephones Cables Ltd Improvements in or relating to the joining of wires particularly fine wires used in the manufacture of electric coils
US2523291A (en) * 1945-09-05 1950-09-26 Int Standard Electric Corp Electric welding fixture

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1299150A (en) * 1918-08-16 1919-04-01 Frank L Dyer Method of manufacturing spark-plugs.
US1489093A (en) * 1919-12-08 1924-04-01 Said Mershon Welding aluminum
US1613957A (en) * 1923-01-19 1927-01-11 Westinghouse Lamp Co Method and machine for electric welding
US1706880A (en) * 1926-12-21 1929-03-26 Westinghouse Lamp Co Method of basing and soldering
US2159916A (en) * 1937-12-01 1939-05-23 Vanco Products Process for electric flash percussive welding
GB558472A (en) * 1942-07-03 1944-01-06 Standard Telephones Cables Ltd Improvements in or relating to the joining of wires particularly fine wires used in the manufacture of electric coils
US2523291A (en) * 1945-09-05 1950-09-26 Int Standard Electric Corp Electric welding fixture

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2832883A (en) * 1951-12-26 1958-04-29 Gen Electric Electric lamp manufacture
US2809279A (en) * 1954-11-24 1957-10-08 Gen Electric Lamp basing apparatus
US3361893A (en) * 1964-08-18 1968-01-02 Sylvania Electric Prod Lamp basing method
US4091259A (en) * 1976-06-08 1978-05-23 Matsushita Electric Industrial Co., Ltd. Method for welding lead wires together
US4166943A (en) * 1976-06-08 1979-09-04 Matsushita Electric Industrial Co., Ltd. Apparatus for welding lead wires together
US5039905A (en) * 1989-07-04 1991-08-13 U.S. Philips Corporation Welding connection for an electric lamp
CN117943652A (zh) * 2024-03-26 2024-04-30 山西星心半导体科技有限公司 一种led灯泡针脚焊接机

Also Published As

Publication number Publication date
GB718690A (en) 1954-11-17
NL94452C (pt)
DE936464C (de) 1955-12-15
BE522412A (pt)

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